Hand-held power tool



Feb. 24, 1948.

w. F. ALLENBY 2,436,540

HANDHELD POWER TOOL Filed Aug. 51, 1944 5 Sheets-Sheet l 5'\ I Ff i ha? BWM q /n' e ATTORNEYS Feb. 24, 1948.

W. 4F. ALLENBY HANDHELD POWER TOOL Filed Aug. 5l, 1944 5 Sheets-Sheet 2 INVENTOR ,7l/Ulm?" 'A Zny QM Y ATTORNEYS Fei). 24, 1948. W F ALLENBY 2,43%540 HANDHELD POWER TOOL Filed Aug. 3l, 1944 3 Sheets-Sheet 3 llmu u mvENTpR MUM/7047A Ze/16,9-

ATTORNEYS Patented Feb. 24, 1948 UNITED STATES PATENT OFFICE HAND-HELD POWER TOOL William F. Allenby, Stratford, Conn., assigner to Casco Products Corporation, Bridgeport, Conn., a corporation of Connecticut Application August 31, 1944, Serial No. 552,185

7 Claims. 1

This invention relates to small handheld electric power tools, and more particularly to improvements in a tool of the type shown in Patents #2,319,194 and #2,339,829, issued to Joseph Youhouse on May l1, 1943, and January 25, 1944, respectively.

Attention is called to my application, Serial No. 668,798, illed May l0, 1946, claiming subjectmatter shown herein.

In tools of this type, characteristics which assume prime importance are lightness -of weight and smallness of size, since a heavy or bulky tool would seriously adversely affect the skill with which the various grinding, drilling and cutting operations may be carried out, especially if the tool is used over a protracted period of time. While it is desirable to -maintain small weight and size, these factors are generally balanced against power and sturdiness, the latter being made sufficient for the practical purposes oi the tool. However, because of the nature oi the work done by small handheld tools of this type, overloading as regard-s power output, applied mechanical pressures, strains and vibrations is quite prevalent, so that carefully designed and calculated 'balances are upset, and damage to and failure of the tool may result.

In the latter-named of the above-mentioned patents, thermo-responsive means are provided for protecting the motor of the tool from burnout during severe or overload conditions of usage by temporarily automatically disconnecting it from the circuit, which as a result renders the tool inoperative for a short period. y

An object of the present invention is to provid a tool of this type in which the cut-out or the motor due to overload is more reliable, in which the cut-out periods are reduced in duration and frequency to a minimum so that the tool will withstand more overload without becoming inoperative, and also in which means are provided for enabling the tool structurally to withstand greater pressures, strains and vibrations especialy during such overloads, where considerable heat may be involved, thus enabling the tool to generally have greater usefulness.

This is accomplished by the provision, in a tool of the above type, of a combination of motor and cast-metal subframe in intimate heat-conducting relation with the motor, for supporting the armature and field of the latter substantially as a unitary rigid structure. The subframe is of cast metal, as for instance aluminum, preferably having a comparatively high heat conductivity, and is cut away to permit yeiiicient ventilation of the armature while at the same time retaining a large heat-dissipating area and structural rigidity, the entire assembly of frame and motor being enclosed in an insulating casing having Ventilating perforations and a shape to enable it to be gripped by and held in the hand. The cast-metal subframe is located in the path of air currents created by fan blades ol the motor armature, so that rapid and eiiicient dissipation of heat from the frame is provided for. Thus, a considerable amount of the excessive heat generated in the motor windings due to continued use or over;oa:l will be quickly carried onc and dissipated by the cast-metal subirame, and by preventing the heat from accumulating, the subrame will keep the motor cooler so that the thermo-protective device of the tool does not so frequently open the motor circuit.

To further enable the tool to safely carry overloaols without damage, means are provided to assure a more reliable response of the thermorespons-ive cut-out to dangerous overheating of the motor by an arrangement which enables radiated heat, as well as conducted heat and convection heat to act on the cut-out. This is accomplished by a mounting for the bimetallic thermostat arm whereby its broad side is exposed directly to the motor armature, to receive radiated heat from the latter. Thus the motor of the tool may be consistently overloaded without danger of burnout.

Also, the heating of the motor will not adversely aiect the rigid subframe to misalign, or impair the running of, the motor since the frame is a rigid metal casting having reinforcing webs, nor will the casting yield when subjected to heavy vibrations, pressures or strains associated with the overloading of the motor as resulting from manipulation of the tool.

By the use of aluminum or a light-weight alloy for casting the subirame of the tool, and by providing cut-out portions serving for ventilation, thel weight of the tool is not appreciably increased, nor is its size, yet as pointed out above, the structural strength and load capacity are considerably increased, thus resulting in a tool of increased usefulness.

Associated and cooperating with the thermoresponsive eut-out is an improved and simplified switching mechanism having a detent action, especially when in on position, which maintains the motor circuit closed despite the excessive vibrations to which the tool might be subjected during normal or even dlllicult or heavy work. In the switch, a pair of contacts are bridged by a movable spring-urged member, the contacts being shaped and mounted to provide a cavity between them which makes possible a detent action so that the pressure of the movable member maintains the latter at rest in its bridging circuitclosing position over the cavity whereby the effect of vibration serves to seat rather than dislodge the movable member.

Combining to provide a tool according to the present invention adapted to withstand severe or overload conditions of use, such as severe vibration, strains, etc., is an improved tool-bit carrier provided with simpliiied abutment means for engaging the square-cut end of the armature drive shaft, to prevent shifting of the carrier with relation to the shaft during extreme conditions of pressure on the tool bit, or of vibration re# sulting from such pressure during operation of the tool. In conjunction with this, an improved thrust-bearing means is provided at the other end of the armature shaft for withstanding the comparatively heavy vibratory thrust forces over protracted periods of use.

The eifect on the armature windings of vibration of the tool is minimized by the provision, according to this invention, of a rigidly mounted supporting band between the commutator and armature coils to which band the lead wires from the armature are bound. In the illustrated embodiment of the invention the supporting band is made as an integral part rof the molded commutator body, so that the lead wires may be secured to the commutator structure by a strong vibration-resistant binding in addition to the soldered electrical connections commonly employed, which latter, if not reinforced by additional means, often work loose when subjected to vibrating forces because of variations in soldering technique and skill employed.

Other features and advantages will hereinafter appear.

In the accompanying drawings- Figure 1 is an axial section of a handheld power tool embodying the present invention.

Fig. 2 is an axial section of the tool, taken at right angles to the section of Fig. 1.

Fig. 3 is a fragmentary cross-section taken on the line 3-3 of Fig. 1.

Fig. 4 is a face view of the cast-metal subframe of the tool.

Fig. 5 is a side elevation of the subframe.

Fig. 6 is a face view of the switch plate and contacts of the tool.

Fig. '7 is a section taken on the line 1--1 of Fig. 6.

Fig. 8 is an inside view of one of the casing halves, slightly modied, and

Fig. 9 is an inside view of the other casing half, slightly modied.

Referring to Figs. 1 and 2, the tool of the present invention comprises an electric motor having an armature ill and disk commutator Il, the latter being engaged by brushes l2, and the motor having a ield structure I3 and field coil I4 Afor cooperating with the armature.

A tool chuck l5 is mounted on one end of the armature shaft I6 to rotate with the latter and carry a tool for performing work, the chuck, armature shaft and other parts of the motor being enclosed in a casing comprising a pair of tubular telescoping sleeves ll and I8 joined with half shells liiand 2B, which latter form the main body portion o-f the casing.

According to the present invention, a rigid cast-metal subframe 2l, Figs. 2, 3, 4 and`5, is pro- .Ajected to a iconsiderable overload without causing overheating 0r misalignment of the motor,

since the heat is quickly and efficiently carried off, and since the motor parts are rigidly held 'against `displacement by the cast-metal subfr-ame, Vand 'the tool does not become uncomfortably hot to the touch during use.

Referring to Figs. 1, 2, 4 and 5, the subframe 2| has an externally threaded collar portion Zia on which the sleeve IS of the casing is threaded, the latter having a circular shouldered ange Vl'caencircling semi-circular end portions 19a and 20a of the vcasing half-shells to hold the latter in assembled position. The casing shown in Figs. l and 2 is a slightly modied `form adapted to engage the connector 'cord directly, while ythe -halfshells shown in Figs. 8 and 9 are adapted toreceive a plug connector similar to that illustrated in the aforementioned patents.

As shown in Figs. 1 and 2, the eld core structure lI3 is secured directly to lthe subframe 2i by studs and nuts 22, the subframe Aand field structure having va comparatively large area of vcontact as shown by the line 2'3, Fig. v2, andthe dotted lines 24, Fig. 1, so that the subframe is in `intimate heat-receiving relation with the field structure.

The armature lo of the motor, carried bythe shaft I6, is journaled in bearing `sleeves 25 and 26, the latter being press-tted in the collar portion 2Ia of the subframe, and the sleeve 25 being fitted into a metal Abearing vblock 2l mounted -by screws 28 on the body portion 2lb of the sub'- frame. As seen in Fig. 4, the body portion 2lb of the `subframe is cut-away to provide a Ycomparatively large ventilation aperture 2'lc which also provides clearance -for the armature laminations lila and also reduces considerably the weight of the subframe. The Width'of the aperture '2 Ic is preferably lapproximately equal to the diameter of the armature windings wb, to provide a large area for circulating air currents. Also, the bearing block V2"! is cut away at 21a to provide for Vlightness yand to permit vcooling Vair currents to pass through.

By this construction heat which is vgenerated inthe eld coil IQ and transmitted to the field structure I3 will :be quickly carried off by the cast-metal subframe 2|, due to the Vlarge surface 'contact between said structure and subframe. Likewise, heat generated in the larmature windings lb and transmitted to the laminations Illa and shaft i6 will be 4carried oif through the bearing sleeves 25 vand 'Zfto the vsubframe 2i for ldissipation by 'the latter. Moreover, the heating of the subframe 21, and the mechanical stresses resulting from operationof the tool will not ldistort or otherwise deform the frame, so that proper alignment of the armature Hl and field structure i3 will be maintained, as well as alignment of the bearing sleeves 2'5 and 26, thus preventing the shaft "i6 from binding.

The subframe 2i 'is provided Vwith a pair of recesses 2id in which the brushes I2 are carried, the latter being press-fitted into the recesses with 's'tripinsulation 29, "as shown in Fig. Y1. Accord# ingly, the brushes I2 will also be maintained in accurate alignment regardless of Working stresses existing in the tool, since the brushes are carried by rigid cast metal.

Referring to Figs. 2 and 9, the shell I of the casing is provided with elongate apertures Ich some of which are located adjacent the large aperture 2Ic of the subframe 2i, and the shell 20 of the casing, Fig. 8, provided with similar apertures 2%, so that an efficient ventilation of the motor is provided. The air currents set up by the rapidly rotating armature lil may thus travel laterally out of the casing shells IQ and 29 and in so doing carry heat from the motor armature and also from the cast-subframe 2l, the latter thereby dissipating at a rapid rate the heat it receives from the motor armature and field. Air currents may also pass through the recess 21a in the bearing block 2l to cool the latter. Preferably, the subframe 2l and bearing block 2 are cast of aluminum which has a high heat-conductivity factor, so that the cooling of the motor is further effectively carried out.

As shown in Figs. 1 and 2 the metal sub-frame 2| is spaced from the half shell i9 in an area surrounding the armature and laterally thereof, and the frame 2| does not extend in the region of the eld coil I4 but instead the latter is spaced a substantial distance from the half-shells i9 and 2B, thereby effectively preventing conduction of heat from the frame and the field coil to the shell, and as a result the shell halves remain relatively cool during operation of the tool.

To increase the ventilation of the motor, the armature Il) is provided with a fanblade structure 30, Fig, 1, which functions in the manner of a centrifugal blower so that air currents are set up under a constant pressure during operation of the tool.

Referring to Fig. l, means are provided, associated with the shaft Iii, for the purpose of enabling the tool to successfully withstand considerable thrust stresses, including those resulting from severe vibrations incidental to the nature of the operations for which the tool is used. The chuck I5 is shown as including a sleeve ld which is secured on the end of the shaft l5 by a pair of oppositely located set screws Ib. For engagement with the end of the shaft l, there is provided a pin 3l diametrically disposed in the sleeve Ia and secured in place in a suitable manner as by upsetting the ends of the pin. At the lower end of the shaft I6 an improved wearresistant thrust bearing is provided in the form of a hardened steel ball 32 having a diameter substantially equal to that of the shaft l@ and engaging the ground end surface of the latter. `A cupped thrust plate 33 is secured to the bearing block 21 by means of rivets 35i, the cupped portion of the plate nesting the ball 32 and retaining the latter in the position shown wherein it engages not only the plate and shaft I5 but also the inner surface of the bearing sleeve 25. During rotation of the shaft I6 the ball 32, which is free to rotate, will be continuously turning in various directions as determined by the changing stresses on it, and therefore the wearing of the ball will take place uniformly, thus providing a sturdy bearing structure having long life. The bearing sleeves 25 and 26 are preferably of material having inherent lubrication, such as Oilite bearings. By virtue of the thrust means comprising the ball 32 and the pin SI, the rotating part of the tool is adapted to withstand sudden and severe thrust loads such as may be normally met when the tool is used for grinding or cutting operations on workpieces of hard material, or when the tool is being overloaded.

To further adapt the tool to withstand severe vibrations, an improved armature and commutator vassembly is provided wherein the lead wires from the armature coils Iilb may be securely bound at the points where they extend from the coils to the commutator II, thereby preventing loosening of these leads throughout the useful life of the tool, As shown in Fig. 1, the commutator il which is of the disk type, comprises a molded hub IIa having embedded metallic segments ilb to which the armature leads I0c are soldered. The molded hub IIa of the commutator is provided with an integral skirt IIc extending toward the armature laminations Illa and enclosing a portion of the windings Ib. The armature lead wires Ic extend from the coils It?) past the periphery of the skirt Iic to the commutator segments IIb. To bind the lead wires Iic securely to the skirt IIc, a strip of adhesive tape S5 is Wound around the wires and the skirt, the tape preferably being lapped on itself for approximately one-half turn. At the time that the armature assembly is completed, including the placing of the tape 35, the entire assembly is dipped in varnish and baked, thereby causing the tape 35 to be securely held in place. rfhus the leads Ic may be securely bound against the skirt Hc, thereby eliminating unsupported stretches of wire which might, as a result of severe vibrations during continued use of the tool, ultimately break free from the commutator segments and cause failure of the tool.

By the provision of the cast-metal subframe 2l, preferably of aluminum having high thermoconductivity, the operating temperature of the motor is maintained at a comparatively low value, which permits a greater overloading of the tool than was heretofore possible. In connection with such overloading the invention provides an improved heat-responsive automatic circuit breaker which reliably functions to disconnect the motor should the overloading become excessive and approach the danger point. This automatic cutout is associated with an improved vibrationresistant switch means so that more reliable operation of the tool is obtained during protracted heavy-duty work,

As shown in Figs. 2, 6 and 7, the cut-out and switch means is carried by an elongate molded plate 36 secured by screws to the bearing block 2 and collar Zia of the subframe, part of the switch being also carried by the shell 25 of the casing. As shown in Fig. 6, the plate 3S has in its outer face a recess 36a across which a rib 3th extends. An elongate sheet metal contact 31 is secured over the rib 315D, the side edges 37a and 37b of the contact being formed to extend somewhat into the recess 36a at each side of the rib 35h, thereby providing substantially a crowned outer surface on the contact. A second contact 38 is mounted at one edge of the recess 38a substantially level with the surface of the contact El. As shown in Figs. 2 and 7, the plate 36 is provided with apertures so that the contacts Si and 3S may be extended to the underside of the plate and bent over to securely hold them in place. Cooperating with contacts 31 and 3B is a U-shaped spring switch arm 3S, Fig. 2, mounted on an insulating switch button di) carried in a slot 4I in the shell 2%. The spring 39 is formed at its free end to provide a convex surface for engagement with the contacts 31 and 38, the

4act-ion :of fthe `rarrn .being such that it yfunctions las a .detent .to hold the switch vin either 'opencircuit .or 'closedcircuit position. .Referring to Fig. .12, the .arm "3S is .shown .bridging the contacts 3i Aand V38, `thereby 'closing lthe switch circuit. When the arm 353 Lis .in .this bridging position Yits `resiiiency functions to :maintain a positive connection between the contacts 3i and 35, and Vibrations to which the tool may be subjected 4tend to maintain .such connection 4rather than sever fit. Therefore, `the 'tool will be reliable ,in voperation during conditions of ,severe vibratory use. If the button 'l should be imoved'upwardly as viewed in Fig, 2, the arm 39 would ride over and past the .contact Si so as to extend partially Ainto the recess 36a, :thereby retaining the switch in open-circuit position. iCooperating with the contact i3d, .as .shown in Figs. 2 and 6 there is provided abimetallic .arm l2 .secured to the `plate 3'6 by a rivet The arm i2 and the contact 38 are Vprovided with cooperating contact points of suitable metal such as silver. ,Directly ladjacent the bimetallic arm d2, `the plate Se is 4provided with an aperture 36o so 4that heat ,radiated from 4the armature of `the motor may `directly reach the arm l2 .and raise the temperature of the latter, By the provision oi the aperture lc, the arm i2 is heated .by radiation, in addition to its heating by convection and conduction, and therefore the response of the arm to overheating of the motor will bemore "reliable than was heretofore possible.

The switch Aand vcut-out mechanism illustrated .is connected .in series with 'the motor circuit, one lead of the circuit being brought to the contact 37 and the other lead to a terminal strip d connected to the ibase of the bimetallic .ar-m d2.

Variations and modifications may be made Within the scope of this invention and portions of the improvements may be used without others.

I claim:

l. In a portable tool Vhaving a driving motor, a Ycast-metal skeleton frame vfor .rigidly supportying the armature 'and field of the motor in fixed relative positions; an `insulating casing enclosing the motor and skeleton `frame; means carried by the skeleton `frame -for mounting a tool to extend exteriorly of the casing; and vheat-responsive switch means mounted within the casing, for automatically opening the motor circuit in response to overheating of the motor, said switch means being exposed to and receiving heat from the motor armature by radiation, `convection land conduction.

2. In a handheld portable toolhaving a driving motor, an elongate cast-metal skeleton frame 4having bearings at 'its ends fbe'tween which the motor armature is iournaled, said iframe Yhaving a relatively great Awidth exceeding the diameter ci lthe armature core, and having an aperture located intermediate its ends and laterally of 'the armature core, the width of said aperture -approximating the diameter of the armature windn ings and the `frame rigidly carrying the field structure of the motor; centrifugal fan means carried by `the ymotor armature in ljuxtaposition to Athe windings thereof for causing air to be thrown radially from the `armature directly throughthe aperture inthe frame; and an inA sulating casingenclosing the .motor and skeleton frame, having vent openings adjacent vthe aperture of the frame whereby the said air thrown by the -fan :means through the said aperture passes out through the vent openings, to cool the motor.

3.. TheinVention-as dened in claim 2 ,rin which the frame :is :in intimate Yheat-.receiving relation with 'the motor armature and field, and -is cast of high heat-conductivity metal 4thereby :to -conduct heat .trom the motor and Yreduce the operatingr temperature .of same.

4. In a portable tool .for use as va grinder, a rigid, unitary cast metal .skeleton frame having a base portion provided with an integral collar and a bearing in said collar vand having a .second bearing .rigidly connected yto said collar; a motor carried .by the lframe, having :an armature shaft journaled in said bearings, and having a field core secured to said frame, the supporting of the bearings being independent of said lfield core; :a `disli commutator carried kby the shaft adjacent and :facing the :said collar; brushes bearing on .the coinmutator; holders for `the brushes, extending parallel to the shaft and embedded in the collar; a casing enclosing .the frame, said casing including a Afinger-grip rigidly `mounted on `the collar.; Yand means carried by the :armature shaft adjacent the bearing in the said collar, .for mounting a tool `to extend-through the fingergrip and exteriorly of the casing, the motor brushes,.shaft and commutator being rigidly supported wholly by the cast frame and independently of the motor eld core and the casing so that misaiignment of `the shaft bearings, commutator and brushes lis prevented should the casing or eid core become distorted when the tool .is in use.

5. Ina `handheld tool having a driving motor, .a `cast skeleton frame of metal having high heat conductivity and 'comparatively large surface area, rigidly supporting the armature and `iield 4of the motor in xed relative positions, sai-d .armature .and held being in intimate heat-,com ducting relation with the frame whereby the latterdissipates heat from the motor at an eil'icient .rate vwhile rigidly .supporting lsame during overload conditions; and an insulating vcasing adapted to be grasped by hand, enclosing the skeleton frame fto prevent the latter from coming .in contact with an operator, said casing Ibeing spaced from the frame and ,adjoining .portions of the motor in the area surrounding the armatureand Vlaterally thereof to prevent heat conduction from the 'frame and motor Vto the casing in said area.

En ra .handheld poirier-operated tool, a `casing; an :electric .motor .in said casing `having a shaft and tool-receiving .means :connected with the latter; 'switch `means iorcontrolling the motor, including a switch fplate vof insulating material mounted in the .casing, having a pair of juxtaposed recesses; a pair of contacts ,mounted on fthe plate, one between and :extending toward Aboth the recesses and the other extending `from the opposite edge of one recess; a button movably carried by the casing for manual operation from the exterior 'of .the :latter; a resilient metal spring connected to the button having a convexed portion adapted :to :ride .over .the recesses and contacts and bridge the latter when .located over the vrecess between same, the spring providing a `detent action in cooperation with the said recesses and contacts; and a bimetallic arm eX- .posed to and in neat-receiving .relation with the `motor armature and receiving V.heat from the armature by conduction, convection and radiation, said arrn'being mounted on the'switch plate to engage one of said contacts .during `normal operation of the motor, and `to disengage said ycontactwhen the motorlbecoines overheated.

"2. A portablehand-held grinding 'tool comprising a rigid unitary elongate cast metal skeleton frame having bearings at its opposite ends; a motor carried by the frame, having an armature shaft coeXtensive With the frame and journaled in said bearings; an elongate insulating casing enclosing the frame and motor, and shaped to be held in the hand; a tubular finger grip rigidly secured to one end of the frame and projecting longitudinally thereof and from the casing, one end of said shaft extending through said nger grip; a thrust ball carried in the bearing at the other end of the frame and engaging the frame and other end of the armature shaft to oppose thrust forces on the shaft; and means carried by the one end of the armature shaft for mounting a tool bit to extend through the finger grip and exteriorly of the latter and the casing, the thrust forces on the shaft resulting from engagement of the tool bit with the Work being transmitted directly to the finger grip through the thrust ball and rigid cast metal frame Without passing through the insulating casing.

WILLIAM F. ALLENBY.

REFERENCES CITED The following references are of record in the le of this patent:

Number 2 Number UNITED STATES PATENTS Name Date Sparks Dec. 24, 1912 Redman Sept. 9, 1924 Kochner Aug. 19, 1941 Youhouse Oct. 7, 1941 Henninger May 12, 1942 Tucker Aug. 4, 1942 Youhouse Jan. 25, 1944 Kochner Aug. 22, 1944 Clare Mar. 22, 1921 Luthy Oct. 2, 1934 Mortensen July 5, 1932 Oldenburg Jan. 3, 1933 Jepson Mar. 11, 1941 Zschau Jan. 23, 1940 Mizer July 2, 1918 FOREIGN PATENTS Country Date Austria Dec. 27, 1933 

